U.S. patent application number 13/707258 was filed with the patent office on 2013-06-27 for coil parts and method of manufacturing the same.
This patent application is currently assigned to C/O SAMSUNG ELECTRO-MECHANICS CO., LTD.. The applicant listed for this patent is c/o Samsung Electro-Mechanics Co., LTD.. Invention is credited to Yong Suk Kim, Jeong Bok Kwak, Sang Moon Lee, Sung Kwon WI, Young Seuck Yoo.
Application Number | 20130162385 13/707258 |
Document ID | / |
Family ID | 48653947 |
Filed Date | 2013-06-27 |
United States Patent
Application |
20130162385 |
Kind Code |
A1 |
Kwak; Jeong Bok ; et
al. |
June 27, 2013 |
COIL PARTS AND METHOD OF MANUFACTURING THE SAME
Abstract
The present invention discloses a coil part including: a first
coil body including a first magnetic substrate, a first coil
pattern provided on the first magnetic substrate, and a first
insulating layer covering the first coil pattern; a second coil
body including a second magnetic substrate corresponding to the
first magnetic substrate, a second coil pattern provided on the
second magnetic substrate to correspond to the first coil pattern,
and a second insulating layer covering the second coil pattern; and
a ferrite composite interposed between the first insulating layer
and the second insulating layer to couple the first coil body and
the second coil body and having a spacer ball inside. According to
the present invention, it is possible to prevent process defects
generated during a manufacturing process of an existing coil part
using a ferrite substrate, improve process efficiency and
productivity, and reduce manufacturing costs.
Inventors: |
Kwak; Jeong Bok;
(Gyeonggi-do, KR) ; Lee; Sang Moon; (Seoul,
KR) ; Yoo; Young Seuck; (Seoul, KR) ; WI; Sung
Kwon; (Seoul, KR) ; Kim; Yong Suk;
(Gyeonggi-do, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
c/o Samsung Electro-Mechanics Co., LTD.; |
Gyeonggi-do |
|
KR |
|
|
Assignee: |
C/O SAMSUNG ELECTRO-MECHANICS CO.,
LTD.
Gyeonggi-do
KR
|
Family ID: |
48653947 |
Appl. No.: |
13/707258 |
Filed: |
December 6, 2012 |
Current U.S.
Class: |
336/200 ;
29/605 |
Current CPC
Class: |
H01F 17/0013 20130101;
Y10T 29/49071 20150115; H01F 41/00 20130101; H01F 41/046 20130101;
H01F 27/303 20130101 |
Class at
Publication: |
336/200 ;
29/605 |
International
Class: |
H01F 17/00 20060101
H01F017/00; H01F 41/00 20060101 H01F041/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 22, 2011 |
KR |
10-2011-0140413 |
Claims
1. A coil part comprising: a first coil body including a first
magnetic substrate, a first coil pattern provided on the first
magnetic substrate, and a first insulating layer covering the first
coil pattern; a second coil body including a second magnetic
substrate corresponding to the first magnetic substrate, a second
coil pattern provided on the second magnetic substrate to
correspond to the first coil pattern, and a second insulating layer
covering the second coil pattern; and a ferrite composite
interposed between the first insulating layer and the second
insulating layer to couple the first coil body and the second coil
body and having a spacer ball inside.
2. The coil part according to claim 1, wherein a first alignment
hole is formed in the first magnetic substrate and a second
alignment hole corresponding to the first alignment hole is formed
in the second magnetic substrate so that the first coil body and
the second coil body are coupled by the ferrite composite in a
state of being aligned through the first alignment hole and the
second alignment hole.
3. The coil part according to claim 1, wherein each of the first
magnetic substrate and the second magnetic substrate is formed with
a size of 4 to 8 inches and a thickness of 0.2 to 1 mm.
4. The coil part according to claim 1, wherein each of the first
magnetic substrate and the second magnetic substrate is made of a
ferrite magnetic material.
5. The coil part according to claim 1, wherein the spacer ball is
made of one of mesophase of liquid crystal, ceramic, and metal.
6. The coil part according to claim 1, wherein the ferrite
composite comprises ferrite powder and resin.
7. The coil part according to claim 6, wherein the resin comprises
adhesive epoxy or polymer.
8. The coil part according to claim 6, wherein the spacer ball is
formed larger than a size of the ferrite powder.
9. The coil part according to claim 1, wherein a first cavity and a
second cavity are formed in a center of the first insulating layer
and a center of the second insulating layer, respectively, and the
ferrite composite is embedded in the first cavity and the second
cavity.
10. A method of manufacturing a coil part comprising: preparing a
first coil body including a first magnetic substrate, a first coil
pattern provided on the first magnetic substrate, and a first
insulating layer covering the first coil pattern; preparing a
second coil body including a second magnetic substrate
corresponding to the first magnetic substrate, a second coil
pattern provided on the second magnetic substrate to correspond to
the first coil pattern, and a second insulating layer covering the
second coil pattern; and coupling the first coil body and the
second coil body by interposing a ferrite composite, which has a
spacer ball inside, between the first insulating layer and the
second insulating layer.
11. The method of manufacturing a coil part according to claim 10,
wherein coupling the first coil body and the second coil body
comprises aligning the first magnetic substrate and the second
magnetic substrate by detecting a first alignment hole formed in
the first magnetic substrate and a second alignment hole formed in
the second magnetic substrate.
12. The method of manufacturing a coil part according to claim 10,
wherein each of the first magnetic substrate and the second
magnetic substrate is formed with a size of 4 to 8 inches and a
thickness of 0.2 to 1 mm.
13. The method of manufacturing a coil part according to claim 10,
wherein each of the first magnetic substrate and the second
magnetic substrate is made of a ferrite magnetic material.
14. The method of manufacturing a coil part according to claim 10,
wherein the spacer ball is made of one of mesophase of liquid
crystal, ceramic, and metal.
15. The method of manufacturing a coil part according to claim 10,
wherein the ferrite composite comprises ferrite powder and
resin.
16. The method of manufacturing a coil part according to claim 15,
wherein the resin comprises adhesive epoxy or polymer.
17. The method of manufacturing a coil part according to claim 15,
wherein the spacer ball is formed larger than a size of the ferrite
powder.
18. The method of manufacturing a coil part according to claim 10,
wherein a first cavity is formed in a center of the first
insulating layer of the first coil body and a second cavity is
formed in a center of the second insulating layer of the second
coil body; and in coupling the first coil body and the second coil
body, the ferrite composite is embedded in the first cavity and the
second cavity.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Claim and incorporate by reference domestic priority
application and foreign priority application as follows:
Cross Reference to Related Application
[0002] This application claims the benefit under 35 U.S.C. Section
119 of Korean Patent Application Serial No. 10-2011-0140413,
entitled filed Dec. 22, 2011, which is hereby incorporated by
reference in its entirety into this application.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to coil parts, and more
particularly, to coil parts capable of improving matching between
coil patterns and increasing horizontal flatness.
[0005] 2. Description of the Related Art
[0006] Electronic products, such as digital TVs, smart phones, and
notebook computers, have functions for data communication in
radio-frequency bands. Such IT electronic products are expected to
be more widely used since they have multifunctional and complex
features by connecting not only one device but also USBs and other
communication ports.
[0007] Here, for higher-speed data communication, data are
communicated through more internal signal lines by moving from MHz
frequency bands to GHz radio-frequency bands.
[0008] When more data are communicated between a main device and a
peripheral device over a GHz radio-frequency band, it is difficult
to provide smooth data processing due to a signal delay and other
noises.
[0009] In order to solve the above problem, an EMI prevention part
is provided around the connection between an IT device and a
peripheral device. However, conventional EMI prevention parts are
used only in limited regions such as specific portions and
large-area substrates since they are coil-type and stack-type and
have large chip part sizes and poor electrical characteristics.
Therefore, there is a need for EMI prevention parts that are
suitable for slim, miniaturized, complex, and multifunctional
features of electronic products.
[0010] A common-mode filter of EMI prevention coil parts in
accordance with the prior art is described below in detail with
reference to FIG. 1.
[0011] Referring to FIG. 1, a conventional common-mode filter
includes a first magnetic substrate 1, an insulating layer 2
provided on the magnetic substrate 1 and including a first coil
pattern 2a and a second coil pattern 2b that are vertically
symmetrical to each other, and a second magnetic substrate 3
provided on the insulating layer 2.
[0012] Here, the insulating layer 2 including the first coil
pattern 2a and the second coil pattern 2b is formed on the first
magnetic substrate 1 through a thin-film process. An example of the
thin-film process is disclosed in Japanese Patent Application
Laid-Open No. 8-203737.
[0013] And, the second magnetic substrate 3 is bonded to the
insulating layer 2 through an adhesive layer 4.
[0014] Further, an external electrode 5 is provided to surround
both ends of a laminate including the first magnetic substrate 1,
the insulating layer 2, and the second magnetic substrate 3. The
external electrode 5 is electrically connected to the first coil
pattern 2a and the second coil pattern 2b through a lead line (not
shown).
[0015] Meanwhile, the insulating layer 2 consists of a first
insulating layer including the first coil pattern 2a and a second
insulating layer including the second coil pattern 2b.
[0016] That is, the first insulating layer including the first coil
pattern 2a is formed by coating an insulating material after
forming the first coil pattern 2a on an upper surface of the first
magnetic substrate 1 through a thin-film process including a photo
process and an exposure process. The second insulating layer
including the second coil pattern 2b is formed by coating an
insulating material after forming the second coil pattern 2b on an
upper surface of the first insulating layer through a thin-film
process including a photo process and an exposure process.
[0017] However, the conventional common-mode filter configured as
above has difficulty in securing flatness of the upper surface of
the first insulating layer. Accordingly, poor matching and
alignment between the first coil pattern 2a and the second coil
pattern 2b are caused by the poor flatness of the upper surface of
the first insulating layer, thus causing poor matching and
alignment between the first magnetic substrate 1 and the second
magnetic substrate 3. Ultimately, due to this problem, impedance
characteristics of the common-mode filter are deteriorated, thus
causing degradation of performance and reliability of the
common-mode filter.
SUMMARY OF THE INVENTION
[0018] The present invention has been invented in order to overcome
the above-described problems and it is, therefore, an object of the
present invention to provide a coil part capable of improving
matching between a first coil pattern and a second coil pattern,
and a method of manufacturing the same.
[0019] It is another object of the present invention to provide a
coil part capable of improving characteristics and performance by
easily forming a magnetic material in a center of a first coil
pattern and a center of a second coil pattern, and a method of
manufacturing the same.
[0020] It is still another object of the present invention to
provide a coil part capable of improving horizontal flatness when
coupling a first coil body and a second coil body, and a method of
manufacturing the same.
[0021] In accordance with one aspect of the present invention to
achieve the object, there is provided a coil part including: a
first coil body including a first magnetic substrate, a first coil
pattern provided on the first magnetic substrate, and a first
insulating layer covering the first coil pattern; a second coil
body including a second magnetic substrate corresponding to the
first magnetic substrate, a second coil pattern provided on the
second magnetic substrate to correspond to the first coil pattern,
and a second insulating layer covering the second coil pattern; and
a ferrite composite interposed between the first insulating layer
and the second insulating layer to couple the first coil body and
the second coil body and having a spacer ball inside.
[0022] Here, a first alignment hole may be formed in the first
magnetic substrate, and a second alignment hole corresponding to
the first alignment hole may be formed in the second magnetic
substrate. Accordingly, the first coil body and the second coil
body may be coupled by the ferrite composite in a state of being
aligned through the first alignment hole and the second alignment
hole.
[0023] At this time, each of the first magnetic substrate and the
second magnetic substrate may be formed with a size of 4 to 8
inches and a thickness of 0.2 to 1 mm.
[0024] Further, each of the first magnetic substrate and the second
magnetic substrate may be made of a ferrite magnetic material.
[0025] Meanwhile, the spacer ball may be made of one of mesophase
of liquid crystal, ceramic, and metal.
[0026] On the other hand, the ferrite composite may include ferrite
powder and resin.
[0027] Here, the resin may include adhesive epoxy or polymer.
[0028] And, the spacer ball may be formed larger than a size of the
ferrite powder.
[0029] Meanwhile, a first cavity and a second cavity may be formed
in a center of the first insulating layer and a center of the
second insulating layer, respectively, and the ferrite composite
may be embedded in the first cavity and the second cavity.
[0030] In accordance with another aspect of the present invention
to achieve the object, there is provided a method of manufacturing
a coil part including the steps of: preparing a first coil body
including a first magnetic substrate, a first coil pattern provided
on the first magnetic substrate, and a first insulating layer
covering the first coil pattern; preparing a second coil body
including a second magnetic substrate corresponding to the first
magnetic substrate, a second coil pattern provided on the second
magnetic substrate to correspond to the first coil pattern, and a
second insulating layer covering the second coil pattern; and
coupling the first coil body and the second coil body by
interposing a ferrite composite, which has a spacer ball inside,
between the first insulating layer and the second insulating
layer.
[0031] The step of coupling the first coil body and the second coil
body may include the step of aligning the first magnetic substrate
and the second magnetic substrate by detecting a first alignment
hole formed in the first magnetic substrate and a second alignment
hole formed in the second magnetic substrate.
[0032] And, each of the first magnetic substrate and the second
magnetic substrate may be formed with a size of 4 to 8 inches and a
thickness of 0.2 to 1 mm.
[0033] Further, each of the first magnetic substrate and the second
magnetic substrate may be made of a ferrite magnetic material.
[0034] Meanwhile, the spacer ball may be made of one of mesophase
of liquid crystal, ceramic, and metal.
[0035] On the other hand, the ferrite composite may include ferrite
powder and resin.
[0036] Here, the resin may include adhesive epoxy or polymer.
[0037] And, the spacer ball may be formed larger than a size of the
ferrite powder.
[0038] Meanwhile, a first cavity may be formed in a center of the
first insulating layer of the first coil body, and a second cavity
may be formed in a center of the second insulating layer of the
second coil body. Accordingly, in the step of coupling the first
coil body and the second coil body, the ferrite composite may be
embedded in the first cavity and the second cavity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] These and/or other aspects and advantages of the present
general inventive concept will become apparent and more readily
appreciated from the following description of the embodiments,
taken in conjunction with the accompanying drawings of which:
[0040] FIG. 1 is a cross-sectional view schematically showing a
common-mode filter of coil parts in accordance with the prior
art;
[0041] FIG. 2 is a cross-sectional view schematically showing a
first embodiment of a coil part in accordance with the present
invention;
[0042] FIGS. 3 to 6 are process cross-sectional views schematically
showing a first embodiment of a method of manufacturing a coil part
in accordance with the present invention;
[0043] FIG. 7 is a cross-sectional view schematically showing a
second embodiment of a coil part in accordance with the present
invention; and
[0044] FIGS. 8 to 11 are process cross-sectional views
schematically showing a second embodiment of a method of
manufacturing a coil part in accordance with the present
invention.
DETAILED DESCRIPTION OF THE PREFERABLE EMBODIMENTS
[0045] Advantages and features of the present invention and methods
of accomplishing the same will be apparent by referring to
embodiments described below in detail in connection with the
accompanying drawings. However, the present invention is not
limited to the embodiments disclosed below and may be implemented
in various different forms. The exemplary embodiments are provided
only for completing the disclosure of the present invention and for
fully representing the scope of the present invention to those
skilled in the art. Like reference numerals refer to like elements
throughout the specification.
[0046] Terms used herein are provided to explain embodiments, not
limiting the present invention. Throughout this specification, the
singular form includes the plural form unless the context clearly
indicates otherwise. When terms "comprises" and/or "comprising"
used herein do not preclude existence and addition of another
component, step, operation and/or device, in addition to the
above-mentioned component, step, operation and/or device.
[0047] Further, embodiments to be described throughout the
specification will be described with reference to cross-sectional
views and/or plan views, which are ideal exemplary drawings of the
present invention. In the drawings, the thicknesses of layers and
regions may be exaggerated for the effective explanation of
technical contents. Therefore, the exemplary drawings may be
modified by manufacturing techniques and/or tolerances. Therefore,
the embodiments of the present invention are not limited to the
accompanying drawings, and can include modifications to be
generated according to manufacturing processes. For example, an
etched region shown at a right angle may be formed in the rounded
shape or formed to have a predetermined curvature. Therefore,
regions shown in the drawings have schematic characteristics. In
addition, the shapes of the regions shown in the drawings exemplify
specific shapes of regions in an element, and do not limit the
invention.
[0048] Hereinafter, preferred embodiments of a coil part and a
method of manufacturing the same in accordance with the present
invention will be described in detail with reference to FIGS. 2 to
11.
[0049] FIG. 2 is a cross-sectional view schematically showing a
first embodiment of a coil part in accordance with the present
invention, and FIGS. 3 to 6 are process cross-sectional views
schematically showing a first embodiment of a method of
manufacturing a coil part in accordance with the present
invention.
[0050] And, FIG. 7 is a cross-sectional view schematically showing
a second embodiment of a coil part in accordance with the present
invention, and FIGS. 8 to 11 are process cross-sectional views
schematically showing a second embodiment of a method of
manufacturing a coil part in accordance with the present
invention.
[0051] A first embodiment of a coil part and a method of
manufacturing the same in accordance with the present invention
will be described with reference to FIGS. 2 to 6.
[0052] Referring to FIG. 2, a first embodiment 100 of a coil part
in accordance with the present invention may include a first coil
body 110, a second coil body 120, and a ferrite composite 130
interposed between the first coil body 110 and the second coil body
120 to couple the first coil body 110 and the second coil body
120.
[0053] The first coil body 110 may include a first magnetic
substrate 111, a first coil pattern 112 provided on the first
magnetic substrate 111, and a first insulating layer 113 covering
the first coil pattern 112.
[0054] The second coil body 120 may include a second magnetic
substrate 121 corresponding to the first magnetic substrate 111, a
second coil pattern 122 provided on the second magnetic substrate
121 to correspond to the first coil pattern 112, and a second
insulating layer 123 covering the second coil pattern 122.
[0055] Here, a first alignment hole (refer to 111a of FIG. 6) may
be formed in the first magnetic substrate 111, and a second
alignment hole (refer to 121a of FIG. 6) corresponding to the first
alignment hole (refer to 111a of FIG. 6) may be formed in the
second magnetic substrate 121. Accordingly, the first coil body 110
and the second coil body 120 may be coupled by the ferrite
composite 130 in a state of being aligned by detection of the first
alignment hole 111a and the second alignment hole 121a.
[0056] Therefore, it is possible to secure exact matching and
alignment between the first coil pattern 112 and the second coil
pattern 122 and between the first magnetic substrate 111 and the
second magnetic substrate 112.
[0057] At this time, the coil part 100 of this embodiment can be
commercialized by cutting both ends of the first magnetic substrate
111 and the second magnetic substrate 121 along dicing lines (refer
to L1 of FIG. 6) after the first coil body 110 and the second coil
body 120 are coupled by the ferrite composite 130.
[0058] And, each of the first magnetic substrate 111 and the second
magnetic substrate 121 may be formed with a size of 4 to 8 inches
and a thickness of 0.2 to 1 mm.
[0059] As an example, each of the first magnetic substrate 111 and
the second magnetic substrate 121 may be formed in the shape of a
square plate with a size of 40 mm wide and 40 mm long on the plane
and a thickness of 0.25 mm.
[0060] Further, each of the first magnetic substrate 111 and the
second magnetic substrate 121 may be made of a ferrite magnetic
material.
[0061] Meanwhile, the ferrite composite 130 may include ferrite
powder and resin and have a spacer ball 131 inside.
[0062] Here, the resin may include adhesive epoxy or polymer.
[0063] And, the spacer ball may be made of one of mesophase of
liquid crystal, ceramic, and metal.
[0064] At this time, the spacer ball may be formed larger than a
size of the ferrite powder.
[0065] Accordingly, when coupling the first coil body 110 and the
second coil body 120 using the ferrite composite 130, as the spacer
ball 131 uniformly maintains the interval between the first
insulating layer 113 and the second insulating layer 123 along a
horizontal direction, it is possible to improve horizontal flatness
between the first coil body 110 and the second coil body 120.
[0066] In a method of manufacturing the coil part 100 of this
embodiment configured as above, as shown in FIG. 3, a first
magnetic substrate 111 having first alignment holes 111a at both
ends is prepared.
[0067] Next, as shown in FIG. 4, a first coil pattern 112 is formed
in a spiral shape on an upper surface of the first magnetic
substrate 111 through a thin-film process, and the first coil
pattern 112 is covered with a first insulating layer 113.
[0068] Here, an input lead pattern 112a and an output lead pattern
112b for input and output of electricity of the first coil pattern
112 may be formed on the first insulating layer 113.
[0069] At this time, the input lead pattern 112a may be formed in
an outer end portion of the first coil pattern 112, and the output
lead pattern 112b may be electrically connected to an inner end
portion of the first coil pattern 112.
[0070] Next, as shown in FIG. 5, a ferrite composite 130 is
laminated on an upper surface of the first insulating layer
113.
[0071] After that, as shown in FIG. 6, a second coil body 120
manufactured with the same structure and method as the first coil
body 110 is laminated on an upper surface of the ferrite composite
130 to couple the first coil body 110 and the second coil body 120
by the ferrite composite 130.
[0072] At this time, the second insulating layer 123 of the second
coil body 120 may face the first insulating layer 113 by the
ferrite composite 130, and a spacer ball (refer to 131 of FIG. 2)
may be included inside the ferrite composite 130.
[0073] And, after coupling the first coil body 110 and the second
coil body 120 by the ferrite composite 130, it is possible to
commercialize the coil part of this embodiment by cutting both ends
of the first magnetic substrate 111 and both ends of a second
magnetic substrate 121 along dicing lines L1.
[0074] Next, a second embodiment of a coil part and a method of
manufacturing the same will be described with reference to FIGS. 7
to 11.
[0075] Referring to FIG. 7, a second embodiment 200 of a coil part
in accordance with the present invention may include a first coil
body 210, a second coil body 220, and a ferrite composite 230
interposed between the first coil body 210 and the second coil body
220 to couple the first coil body 210 and the second coil body
220.
[0076] The first coil body 210 may include a first magnetic
substrate 211, a first coil pattern 212 provided on the first
magnetic substrate 211, and a first insulating layer 213 covering
the first coil pattern 212.
[0077] The second coil body 220 may include a second magnetic
substrate 221 corresponding to the first magnetic substrate 211, a
second coil pattern 222 provided on the second magnetic substrate
221 to correspond to the first coil pattern 212, and a second
insulating layer 223 covering the second coil pattern 222.
[0078] Meanwhile, in the coil part 200 in accordance with this
embodiment, unlike the above-described first embodiment, a first
cavity 213a and a second cavity 223a may be formed in a center of
the first insulating layer 213 and a center of the second
insulating layer 223, respectively.
[0079] Accordingly, in this embodiment, the ferrite composite 230
may be embedded in the first cavity 213a and the second cavity 223a
when coupling the first coil body 210 and the second coil body
220.
[0080] Meanwhile, a first alignment hole (refer to 211a of FIG. 11)
may be formed in the first magnetic substrate 211, and a second
alignment hole (refer to 221a FIG. 11) corresponding to the first
alignment hole (refer to 211a of FIG. 11) may be formed in the
second magnetic substrate 221. Accordingly, the first coil body 210
and the second coil body 220 may be coupled by the ferrite
composite 230 in a state of being aligned by detection of the first
alignment hole 211a and the second alignment hole 221a.
[0081] Therefore, it is possible to secure exact matching and
alignment between the first coil pattern 212 and the second coil
pattern 222 and between the first magnetic substrate 211 and the
second magnetic substrate 221.
[0082] At this time, the coil part 200 of this embodiment can be
commercialized by cutting both ends of the first magnetic substrate
211 and the second magnetic substrate 221 along dicing lines (refer
to L2 of FIG. 11) after the first coil body 210 and the second coil
body 220 are coupled by the ferrite composite 230.
[0083] And, each of the first magnetic substrate 211 and the second
magnetic substrate 221 may be formed with a size of 4 to 8 inches
and a thickness of 0.2 to 1 mm.
[0084] As an example, each of the first magnetic substrate 211 and
the second magnetic substrate 221 may be formed in the shape of a
square plate with a size of 40 mm wide and 40 mm long on the plane
and a thickness of 0.25 mm.
[0085] Further, each of the first magnetic substrate 211 and the
second magnetic substrate 221 may be made of a ferrite magnetic
material.
[0086] Meanwhile, the ferrite composite 230 may include ferrite
powder and resin and have a spacer ball 231 inside.
[0087] Here, the resin may include adhesive epoxy or polymer.
[0088] And, the spacer ball 231 may be made of one of mesophase of
liquid crystal, ceramic, and metal.
[0089] At this time, the spacer ball 231 may be formed larger than
a size of the ferrite powder.
[0090] Accordingly, when coupling the first coil body 210 and the
second coil body 220 using the ferrite composite 230, as the spacer
ball 231 uniformly maintains the interval between the first
insulating layer 213 and the second insulating layer 223 along a
horizontal direction, it is possible to improve horizontal flatness
between the first coil body 210 and the second coil body 220.
[0091] In a method of manufacturing the coil part 200 of this
embodiment configured as above, as shown in FIG. 8, a first
magnetic substrate 211 having first alignment holes 211a at both
ends is prepared.
[0092] Next, as shown in FIG. 9, a first coil pattern 212 is formed
in a spiral shape on an upper surface of the first magnetic
substrate 211 through a thin-film process, and the first coil
pattern 212 is covered with a first insulating layer 213.
[0093] Here, an input lead pattern 212a and an output lead pattern
212b for input and output of electricity of the first coil pattern
212 may be formed on the first insulating layer 213.
[0094] At this time, the input lead pattern 212a may be formed in
an outer end portion of the first coil pattern 212, and the output
lead pattern 212b may be electrically connected to an inner end
portion of the first coil pattern 212.
[0095] And, a first cavity 213a and a second cavity 223a are formed
in a center of the first insulating layer 213 and a center of a
second insulating layer 223, respectively.
[0096] Next, as shown in FIG. 10, a ferrite composite 230 is
laminated on an upper surface of the first insulating layer
213.
[0097] After that, as shown in FIG. 11, a second coil body 220
manufactured with the same structure and method as the first coil
body 210 is laminated on an upper surface of the ferrite composite
230 to couple the first coil body 210 and the second coil body 220
by the ferrite composite 230.
[0098] At this time, the second insulating layer 223 of the second
coil body 220 may face the first insulating layer 213 by the
ferrite composite 230. Accordingly, the ferrite composite 230 may
be embedded in the first cavity 213a and the second cavity 223a by
a coupling force of the first coil body 210 and the second coil
body 220.
[0099] Here, the ferrite composite 230 may be formed in a gel state
to be easily embedded in the first cavity 213a and the second
cavity 223a, and a spacer ball (refer to 231 of FIG. 7) may be
included inside the ferrite composite 230.
[0100] And, after coupling the first coil body 210 and the second
coil body 220 by the ferrite composite 230, it is possible to
commercialize the coil part of this embodiment by cutting both ends
of the first magnetic substrate 211 and both ends of the second
magnetic substrates 221 along dicing lines L2.
[0101] As described above, according to the coil part and the
method of manufacturing the same in accordance with the present
invention, it is possible to improve matching between a first coil
pattern and a second coil pattern by bonding a first coil body and
a second coil body using a ferrite composite including a spacer
ball.
[0102] And, according to the coil part and the method of
manufacturing the same in accordance with the present invention, it
is possible to improve characteristics and performance of a coil
part by embedding a ferrite composite in a center of a first coil
pattern and a center of a second coil pattern to smoothly increase
a flow of magnetic flux.
[0103] Further, according to the coil part and the method of
manufacturing the same in accordance with the present invention, it
is possible to improve impedance characteristics and thus improve
performance of a coil part due to exact alignment between coil
patterns by increasing horizontal flatness when coupling a first
coil body and a second coil body.
[0104] The foregoing description illustrates the present invention.
Additionally, the foregoing description shows and explains only the
preferred embodiments of the present invention, but it is to be
understood that the present invention is capable of use in various
other combinations, modifications, and environments and is capable
of changes and modifications within the scope of the inventive
concept as expressed herein, commensurate with the above teachings
and/or the skill or knowledge of the related art. The embodiments
described hereinabove are further intended to explain best modes
known of practicing the invention and to enable others skilled in
the art to utilize the invention in such, or other, embodiments and
with the various modifications required by the particular
applications or uses of the invention. Accordingly, the description
is not intended to limit the invention to the form disclosed
herein. Also, it is intended that the appended claims be construed
to include alternative embodiments.
* * * * *